Split Bolt Connectors – Complete Guide & Product Catalog

At Conversions Tech, our split bolt connectors provide safe, durable, and code-compliant solutions for splicing and terminating electrical conductors. Whether you’re joining copper to copper, copper to aluminum, or working on grounding applications, split bolts deliver unmatched mechanical strength and conductivity.

What is a Split Bolt Connector?

A split bolt connector is a heavy-duty mechanical fastener designed to join two or more electrical conductors. Its split design allows wires to be wrapped around a center bolt, then clamped securely with a pressure nut. This ensures high conductivity, corrosion resistance, and long-lasting performance, especially in power distribution and grounding systems.

Applications of Split Bolts

• Splicing Conductors – joining copper or copper/aluminum wires in distribution circuits.
• Grounding – bonding grounding rods, neutral conductors, or building steel.
• Direct Burial – with insulating tape, split bolts are suitable for underground connections.
• Industrial & Utility Power – used in switchgear, panels, and heavy machinery wiring.

Types of Split Bolt Connectors

Conversions Tech manufactures a full range of split bolt connectors in sizes from 6 AWG to 600 MCM. Options include:

• Copper Split Bolts – for copper-to-copper splices, UL listed for grounding and bonding.
• Tin-Plated Bronze Split Bolts – prevents galvanic corrosion when connecting copper to aluminum.
• Heavy-Duty / Wide Range Split Bolts – designed for large conductors up to 600 MCM.

Why Choose Conversions Tech Split Bolts?

• UL/CSA Listed – ensuring compliance with NEC and local electrical codes.
• High Conductivity Alloy – 99% IACS copper alloy for low resistance connections.
• Corrosion Protection – tin-plated options for copper/aluminum compatibility.
• Range of Sizes – covers everything from #6 AWG to 600 MCM conductors.
• Direct OEM Alternative – equivalent to Burndy, Blackburn, Ilsco, and NSi split bolts at competitive pricing.

Split Bolt Sizing Guide (AWG/MCM)

Selecting the correct size is critical for performance and code compliance. Below is a quick guide:

Installation Tips

1. Strip insulation carefully without nicking conductor strands.
2. Insert conductors fully into the split bolt connector.
3. Tighten the nut to manufacturer’s recommended torque values.
4. Wrap with rubber insulating tape and vinyl tape for dielectric protection and corrosion resistance.

Split Bolts vs. Other Connectors

How do split bolts compare to other mechanical connectors?

• Split Bolt vs. Polaris Lug – Split bolts are more compact and cost-effective; Polaris lugs offer easier re-termination.
• Split Bolt vs. Compression Lug – Split bolts don’t require a crimp tool but compression lugs can be faster in high-volume installs.
• Split Bolt vs. Wire Nut – Wire nuts are for residential/light use; split bolts handle heavy gauge conductors and code-compliant grounding.

Competitor Comparison

Conversions Tech split bolts are engineered to match or exceed leading brands:

• Burndy KS Series
• Blackburn (Thomas & Betts / ABB)
• Ilsco SL Series
• NSi Industries

Our connectors provide equal performance at a more competitive cost, with faster lead times and excellent logistics support.

Shop Split Bolt Connectors

Browse our complete catalog of split bolt connectors available for fast shipping:

Shop Split Bolt Connectors →

Frequently Asked Questions (FAQ)

Can split bolts be used with aluminum conductors?

Yes, when using a tin-plated bronze split bolt designed for copper-to-aluminum applications.

Are split bolts code compliant?

Yes, UL/CSA listed split bolts meet NEC requirements for grounding and splicing.

What sizes are available?

Conversions Tech split bolts cover 6 AWG through 600 MCM conductor sizes.

Can split bolts be buried?

Yes, when wrapped with insulating tape per NEC 110.14(B) guidelines.